Apparatus and methods for product orientation and hole healing applications

ABSTRACT

Articles are transferred from an article supply conveyor to an article receiving conveyor while the transferring articles are selectively reoriented. When the conveyors are in parallel, a travelling article reorienting turret seeks articles following an article absence or hole on the supply conveyor and transfers the following article to a next-in-line position on the receiving conveyor to cure or avoid holes of articles on the receiving conveyor.

PRIORITY CLAIM

This application is a Continuation of U.S. Ser. No. 15/805,841, filedNov. 7, 2017, which Applicant claims the benefit of the filing date ofNov. 7, 2016 of U.S. Provisional Patent Application Ser. No. 62/418,381,which the applications are herewith incorporated herein in theirentirety by reference.

FIELD OF THE INVENTION

This invention relates to apparatus and methods for selectivelyorienting articles transferring between conveyors and repairing holes orabsences of missing articles in an incoming stream of articles.

BACKGROUND OF THE INVENTION

In packaging equipment, it is common and frequently necessary toreorient a product or article from an orientation in an incoming productor article stream to another orientation prior to loading it into acarton or bin. This need is most common when the incoming product is ofodd shape and requires nesting in the packaging carton, or if the cartoncontains cut outs to showcase a feature of the product. In many cases,the product is roughly rectangular with sides longer than narrower ends,and is conveyed in a single stream with either narrow product end edgeleading or broad side edge leading. The product can be, but is notlimited to articles of various types such as pouches, bars, or trays.

The terms “article” and “product” are used herein interchangeably.

While several prior methods are known for product reorientation inpackaging processes, known systems have inherent problems.

For example, in a packaging apparatus or process, one form of productpackaging may require a specific product reorientation, while the nextform of product packaging may require a different reorientation. Suchrequirements mandate expensive equipment change-out, or downtime forre-adjustment, equipment replacement or the like. It is difficult if notimpossible to accommodate multiple product reorientation configurationsin the same equipment.

Also, where product supply and product receiving conveyors are alignedin parallel directions, the problem of missing articles (or “holes”) inan infeed or article supply line causes waste or downstream issues wherean article is missing, or a formed article or product group is missingone or more of the articles or products. This is especially troublesomewhere product supply at a constant product pitch is anticipated butproduct is missing at a pitch position. Missing product or “holes” inthe product supply line require filing or “healing”, accomplished in thepast only by processes such as incomplete product group rejection,product storage or product collection to fill out incomplete productsupply or product groups, manual product insertions, etc. Theretypically is no apparatus or free excess product at the reorientationstation for hole healing.

SUMMARY OF THE INVENTION

The invention contemplates, without limitation but in various preferredembodiments, apparatus and methods involving an article supply conveyor,an article receiving conveyor and a rotary article transfer turret fortransferring articles from the article supply conveyor to the articlereceiving conveyor, while at the same time selectively reorienting thetransferring articles, and the transfer turret in one embodiment beingmoveable along the article supply conveyor serving to heal or replacemissing articles thereon.

In one embodiment according to the invention, article supply and articlereceiving conveyors are aligned in parallel, and a rotary articletransfer turret is operably disposed between the parallel conveyors fortransferring articles therebetween and selectively rotating transferringarticles. The turret is also moveable along the conveyors to accomplishhole healing, i.e. fill absences on the supply conveyor so there are noarticle absences on the receiving conveyor.

In another embodiment the supply and receiving conveyors areperpendicularly oriented and a rotary article transfer turret isoperably disposed therebetween for selectively orienting transferringarticles, but without hole healing functions.

As used herein, the terms “selective” and “selectively” refer to eitherchanging or not changing the orientation of an article between itsrespective orientation on an article supply conveyor and its orientationon an article receiving conveyor, the apparatus and methods capable ofdoing either.

DESCRIPTION OF FIGURES

FIG. 1 is an illustrative diagrammatic plan view of two parallel counterflow conveyors, with selectively rotating a product, that is initiallytraveling narrow edge leading, 90 degrees while moving the product to aparallel conveyor;

FIG. 2 is an illustrative diagrammatic plan view of two parallel counterflow conveyors, with selectively rotating a product, that is initiallytraveling broad edge leading, 90 degrees while moving the product to aparallel conveyor;

FIG. 3 is an illustrative diagrammatic plan view of two parallel counterflow conveyors, with selectively rotating a product, that is initiallytraveling narrow edge leading, 180 degrees while moving product to aparallel conveyor;

FIG. 4 is an illustrative diagrammatic plan view of two parallel counterflow conveyors, with selectively rotating a product, that is initiallytraveling broad edge leading, 180 degrees while moving product to aparallel conveyor;

FIG. 5 is an illustrative diagrammatic plan view of perpendicularconveyors with selectively rotating a product, that is initiallytraveling narrow edge leading, 90 degrees while moving the product to aperpendicular conveyor;

FIG. 6 is an illustrative diagrammatic plan view of perpendicularconveyors, with selectively rotating a product, that is initiallytraveling broad edge leading, 180 degrees while moving the product to aperpendicular conveyor;

FIG. 7 is an illustrative diagrammatic plan view of perpendicularconveyors, with selectively rotating a product, that is initiallytraveling narrow edge leading, 180 degrees while moving product to aperpendicular conveyor;

FIG. 8 is an illustrative diagrammatic plan view of perpendicularconveyors, with selectively rotating a product, that is initiallytraveling broad edge leading 90 degrees while moving product to aperpendicular conveyor;

FIG. 9 is an illustrative diagrammatic plan view of a U-shaped conveyor,selectively rotating a product, that is initially traveling broad edgeleading, 180 degrees while moving product from one leg of the U-shapedconveyor to the other parallel leg;

FIG. 10 is an illustrative diagrammatic plan view of a U-shapedconveyor, selectively rotating a product, that is initially travelingnarrow edge leading, 180 degrees while moving product from one leg ofthe U-shaped conveyor to the other parallel leg;

FIG. 11 is an isometric view of one form of a transfer turret;

FIG. 12 is a section view of the transfer turret of FIG. 11;

FIG. 13 is an isometric view of the turret of FIGS. 11, 12 with linearactuator or carriage and cable tray for moving the turret up and downstream to manage hole healing;

FIG. 14 is a top view of a product infeed conveyor, a turret with linearactuator and a downstream article receiving conveyor.

FIG. 15 is an isometric view of FIG. 14;

FIG. 16 is an elevation view of FIG. 14;

FIG. 17 is a close-up isometric view of the turret and infeed conveyor;

FIG. 18 is an isometric view, reverse projection of FIG. 15;

FIG. 19 is an elevation view of the turret drive;

FIG. 20 is an isometric view of another form of transfer turretincluding a planetary drive system providing independent control foreach of the re-orienting spindles;

FIG. 21 is a section view of FIG. 20;

FIG. 22 is a plan view of FIG. 20;

FIG. 23 is an elevation view of one spindle of the embodiment in FIG.20; and

FIG. 24 is a reverse isometric view of FIG. 23.

DETAILED DESCRIPTION OF THE INVENTION

Various functional and exemplary applications of the invention aredepicted in FIGS. 1-10. Details of the respective transfer turrets aredescribed in the following two embodiments, and in the followingdescription of Hole Healing.

FIGS. 1-4 illustrate one embodiment of the invention where an article orproduct supply conveyor is oriented in a direction parallel to anarticle or product receiving conveyor.

FIGS. 5-8 illustrate an alternate embodiment of the invention where anarticle or product supply conveyor is oriented in a directionperpendicularly to an article or product receiving conveyor.

FIGS. 9-10 illustrate a variation of FIGS. 1-4 wherein articles orproducts are transferred between parallel runs of the same conveyor, theruns joined in “U”-shaped configuration.

FIGS. 11-24 illustrate features of alternate rotary turrets used ineither alternate embodiment.

Embodiment 1

FIGS. 1-4 illustrate one embodiment of the invention in connection withparallel product supply conveyors 12, 13. A rotating transfer apparatusor turret such as a rotary turret 20 or 30 is operably disposed betweenconveyors 12, 13.

The control of turret 20, 30 being varied to accomplish the transfer andselective orientation of articles on conveyor 12 to another orientationon conveyor 13. Details of the transfer turret 20 or 30 of thisembodiment are described below.

For clarity in describing the embodiments herein, the respectiveproducts or articles have caps or fitments on one narrower end, asshown, and two broader side edges extending between the narrow ends.Other product configurations can be handled as described herein.

FIG. 1 illustrates selectively rotating an article traveling narrow endedge leading 90 degrees while transferring the article to a parallelcounter flowing conveyor 13. Here articles on receiving conveyor 13 arein groups of two, each group having the same article ends oriented tothe same direction and 180 degrees opposite to those articles inadjacent groups of two, for example.

FIG. 2 illustrates selectively rotating an article that is travelingbroad side edge leading 90 degrees while transferring the article to aparallel counter-flowing receiving conveyor 13.

Here, articles 21 are reoriented into groups of two articles with eacharticle in the same group having narrow ends oriented in the samedirection but 180 degrees opposite to those articles in adjacent groupsof two, for example.

FIG. 3 illustrates selectively rotating articles 21 incoming on conveyor12 traveling narrow end leading 180 degrees while transferring articlesto parallel counter-flowing product receiving conveyor 13. Here articleson receiving conveyor 13 are in groups of two, like those in FIG. 2, forexample.

FIG. 4 illustrates selectively rotating articles 21 incoming on conveyor12, traveling broad side edge leading 180 degrees while transferringarticles to parallel, counter flowing receiving conveyor 13.

Articles 21 on conveyor 13 are disposed in groups of two, each orientedin the same direction and 180 degrees opposite to those articles inadjacent groups, for example.

FIGS. 1-4 are illustrative only of the article or product orientation onconveyor 13, and that orientation, or the number of products in a groupmay be easily changed by controlling the selective rotation of thevacuum cups 9 noted above via control of respective servo motors 16.

Turning briefly to FIGS. 9 and 10, these Figs, respectively illustrate asingle U-shaped conveyor 12 having an article supply infeed run 12 a anda parallel article receiving run 12 b. Articles 21 are conveyed towardtransfer turret 20 in one direction and are selectively rotated andtransferred to parallel, counter-flowing receiving run 12 b by transferturret 20.

FIG. 9 is illustrated with respective product orientations as in FIG. 4,while FIG. 10 is illustrated with respective product orientations as inFIG. 3.

Conveyor runs 12 a and 12 b are operatively joined at conveyor section12 c as illustrated.

Otherwise, selectively transferring articles in the apparatus of FIGS. 9and 10 is similar to that of FIGS. 4 and 3, respectively.

Embodiment 2

In a second embodiment of the invention, either a rotary transfer turret20 or a varied rotary transfer turret 30 is useful in transferringproducts 21 from a product or article infeed or supply conveyor 32 to aproduct or article receiving conveyor 33 oriented and extendingperpendicularly to infeed conveyor 32. The turret 20 or 30 is operablylocated at a position to convey product suction cups 35 in a circularpath over conveyor 32 and conveyor 33 to engage, lift and selectivelyrotate articles 21 from conveyor 32 and to then place articles onconveyor 33 in a desired pattern or grouping or into a selectedorientation different from that on conveyor 32.

In the embodiment of FIGS. 5-8 incoming products 21 are selectivelyreoriented to a desired orientation different from that in which theyreach the transfer 20, 30.

In operation, FIG. 5 illustrates selectively rotating a producttravelling narrow end leading on conveyor 32 through 90 degrees toperpendicular receiving conveyor 33.

For example, as in FIG. 6, products on conveyor 33 are selectivelydisposed in groups of two, with each product in a group oriented in thesame direction but at 180 degrees opposite to the products in adjacentgroups.

FIG. 6 illustrates selectively rotating a product 21 traveling broadedge leading 180 degrees while transferring the product to perpendicularconveyor 33. In this regard, and for example, product orientationconveyor 33, is like that of FIG. 5, however incoming productorientation on conveyor 32 of FIG. 6 is 90 degrees different than onconveyor 32 of FIG. 5.

FIG. 7 illustrates selectively rotating a product traveling narrow edgeleading on supply conveyor 32 to perpendicular conveyor 33 and at 180degrees from product orientation on conveyor 32. Thus final productorientation on conveyor 33 is like that of products 21 on conveyor 33 ofFIG. 8, for example, although the incoming product orientation isdifferent.

FIG. 8 illustrates selectively rotating a product traveling broad edgeleading on supply conveyor 32 to perpendicular 33 and at 90 degrees fromproduct orientation on conveyor 32.

It will be appreciated that the orientation of products on conveyor 32of the FIGS. 5-8 and the reorientation, product groups, and number ofproducts in the groups on receiving conveyor 33 can be selectivelyvaried.

Rotary Turret 20

One rotary transfer turret 20 for use in the embodiments of FIGS. 1-10is shown in FIGS. 11-19. It will be appreciated in FIGS. 13-16 that therotary transfer turret 20 is mounted on a carriage 22 carried on linearslide 11 for selective reciprocal motion between and in the samedirection as the parallel extensions of conveyors 12 and 13, and 12 a,12 b.

The rotary transfer turret 20 is provided with a plurality of rotatableproduct or article suction cups 9, each individually rotatable and eachcarried in a circular path extending over the conveyors 12, 13. Thevacuum cups 9 are controllable to pick up articles 21 on conveyor 12,selectively rotate or reorient them as the transfer turret 20 turns, anddeposit them on conveyor 13, in selectively reoriented status.

To this end, cups 9 are mounted on turret apparatus 20 so as to beextensible to engage articles 21, retractable to lift them and thendeposit them on conveyor 13.

Referring to FIGS. 11-19, rotary transfer turret 20 may be of anysuitable construction consistent with the foregoing function. FIGS.11-19 illustrate but one form of suitable transfer turret 20, operablyoriented over the various product article supply and article receivingconveyors. Turret 20 includes a rotating disc or arm 1 on the end of acentral main shaft 2 and contains two or more spindle assemblies 3 thatare able to independently move vertically by a cam follower 4 in a camtrack 5. Central main shaft 2 is driven by a servo motor 16. A secondshaft, the orientation shaft 6, is driven by a second servo motor 16 andgoes through the main shaft 2. At the end of the orientation shaft 6 isa sun gear 7. The sun gear 7 is connected via a gear train to a planetgear 8 at the end of each spindle assembly. By changing the relativespeed between the main shaft 2 and the orientation shaft 6, the spindles3 rotate a programmable number of degrees, from 0 to 360.

At the bottom of each spindle 3 is the vacuum cup 9 that holds theproduct while it is being lifted and selectively rotated. Vacuum to eachspindle 3 is controlled through a vacuum shoe 10 which allows eachspindle to have an independent vacuum source through its travel aroundthe main shaft 2.

The respective spindles, gears and shafts are driven by any suitablemeans such as the servo motors 16 as illustrated.

The article supply conveyor 12 contains a moving supply of product. At aproduct pick point, the cam track 5 will cause the cam follower 4 of thespindle assembly 3 to lower until the vacuum cup 9 operably engages theproduct. The cam track 5 will then raise the spindle assembly 3 liftingthe product off of the article supply conveyor 12. A motor driving theorientation shaft 6 will speed up or slow down, changing the speed ofthe sun gear 7 which in turn selectively changes the orientation of theproduct carried by the spindle assembly 3. At a product place point overthe outgoing article receiving conveyor 13, the vacuum supply to thespindle assembly 3 will be replaced by pressure through the vacuum shoe10 and cause the product to drop onto the outgoing conveyor 13 in aproper orientation and serially for downstream processes, such ascartoning or packaging.

Rotary Turret 30

Reference is made to FIGS. 20-24 respecting rotary transfer turret 30.Similarly functioning parts therein bear the same number as thoseelements of FIGS. 11-19. A spindle assembly 3 is attached to a spindleholding gear 14 which is driven by an externally mounted motor as shown.A suitable servo motor drives the spindle assembly 3 around a centerpost. As the spindle assembly travels over an infeed conveyor 32 in acircular path, the entire spindle assembly 3 can translate vertically,driven by a cam follower in a cam track 5 (as in turret 20), picking upa product using a vacuum or other gripping device. A second externallymounted servo motor controls the spindle orientation gear 15 (FIG. 21)which in turns rotates a planet gear 8 on the end of the spindleassembly 3 to rotate the product a programmable amount orienting theproduct properly for release onto the outgoing conveyor 33. The spindleholding gear 14, the spindle assembly 3, the spindle orientation gear15, and their respective servo motors make up a single spindle unitmoving and selectively orientating product from the infeed to theoutgoing conveyor 33. Multiples of these units may be stacked to havetwo, three, or four independently controlled spindles rotating around acenter shaft. The advantage of this turret 30 over the turret 20described above is that the rotational speed of the spindle around thecenter post and the orientation of the product can be controlledindependently of each other. This allows the spindle assembly to matchthe speed of the infeed 32 and outgoing 33 conveyor regardless of whatthe other spindles are doing. It also allows more time for the productorientation.

Any suitable turret construction can be used, and it will be appreciatedeither turret 20, 30 can be used in each of the embodiments disclosed.

Hole Healing

When the article supply conveyor 12 (or portion 12 a) is oriented ordisposed in parallel to article receiving conveyer 13, (or portion 12b), article holes or spaces on the supply conveyors 12, 12 a (portion 12a) can be healed such that there are no such holes or missing articleson the article receiving conveyors 13, 12 b.

With a constant article stream with no article holes, the turret 20, 30will remain at the same position relative to article pick and placepoints. However, if there is a whole or missing article on the supplyconveyor, this anomaly can be cured.

Thus in this application of article transfer between parallel conveyors12, 13 (FIGS. 1-4) or conveyor portions 12 a, 12 b, (FIGS. 9, 10) therotary turret 20 or 30 used is mounted on a carriage 22 sliding alongslide 11 in parallel to both conveyors or conveyor portions.

In the event that an article 21 is missing on conveyor 12 (or portion 12a) in a position where it is expected to be (i.e. a “hole”) the transfer20 or 30 is moveable in an upstream direction of arrow “A” alongconveyor 12 (12 a) to the next position where an article 21 is located.Thus transfer 20 (or 30) is moveable to the left as illustrated in FIGS.1-4 and 13-16, for example, (Arrow “A”) to pick an article 21 fromconveyor 12 (12 a). Transfer 20, 30 is then operated to deposit the justpicked article 21 on conveyor 13 (12 b) with no hole or absence of anarticle in the articles on conveyor 13 (12 b). The article 21 isselectively reoriented prior to deposit to fill the next serial positionon conveyor 13. Hole healing as well as article reorientation isaccomplished. Said in another way, the turret (20 or 30) “jumps” themissing article space to pick the next available article on the supplyconveyor.

The rate of the conveyors such as conveyor 13 may be adjusted, such asretarded, to accommodate this hole healing operation, and return of thetransfer 20, 30 to its original position.

In addition to the hole healing functions described herein for the firstembodiment, it will be appreciated that the invention in theapplications of both embodiments is capable of varying the pitch ofarticles on the receiving conveyors from that of the incoming articleson the supply conveyors by varying the speeds of the respectiveconveyors.

These and other advantages and modifications can be readily appreciatedby those of ordinary skill in the art without departing from the scopeof the invention and applicant intends to be bound only by the claimsappended hereto.

1-22. (canceled)
 23. An article handling apparatus including: anextended article supply conveyor for conveying articles disposedrandomly about least three article spaces thereon; an extended articlereceiving conveyor disposed operably proximate thereto; an articletransfer element operably disposed between said conveyors, rotaryarticle carrying elements on said transfer element; said transferelement operably movable in a path over both said conveyors; said rotaryarticle carrying elements operable to engage first articles on saidarticle supply conveyor and transfer them to said article receivingconveyor; said rotary article carrying elements being selectivelyrotatable to reorient said transferring first articles from an articlesupply orientation to a second orientation; and said article transferelement moveable in a direction along a direction parallel to theextension of said supply conveyor and between at least said threearticle spaces on said article supply conveyor.
 24. Apparatus as inclaim 23 wherein said article transfer element is rotatable, and saidrotary article carrying elements are moveable in a circular path. 25.Apparatus as in claim 24 wherein said article transfer element ismoveable linearly in a path along said article supply conveyor to atleast said three spaces.
 26. Apparatus as in claim 25 wherein saidarticle transfer element is operable to engage and transfer a firstarticle on said article supply conveyor to said article receivingconveyor, and is then moveable past an article space on said articlesupply conveyor to a following article space on said article supplyconveyor.
 27. Apparatus as in claim 26 wherein said article transferelement is operable to engage a following article at a third articlespace and is moveable to transfer the following article to said articlereceiving conveyor immediately adjacent said first article on saidarticle receiving conveyor.
 28. Apparatus as in claim 27 wherein saidtransfer element selectively orients said following article whiletransferring it.
 29. Article handling apparatus comprising: a firstarticle conveyor; a second article conveyor parallel to said firstconveyor; a rotary turret operably moveable for operable dispositionalong said first article conveyor between said conveyors for engaging,selectively reorienting and transferring first articles from a firstorientation on said first article conveyor to a second orientation onsaid second article conveyor; said rotary turret moveable in an upstreamdirection along said first article conveyor for engaging and reorientingsucceeding articles from upstream locations on said first articleconveyor, and then moveable in an opposite direction for transferringengaged succeeding articles to positions on said second article conveyorimmediately respectively following said first articles thereon.